64016-0205 Spec Sheet Datasheet by Molex

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Hand Crimp TooHor0156"KKTM and 0.062" Termina‘s /'\® molex V Prod ucls
Hand Crimp Tool for 0.156 KK and 0.062 Terminals
Doc No: ATS-640160205 Release Date: 06-03-08 UNCONTROLLED COPY Page 1 of 6
Revision: B Revision Date: 06-03-08
ServiceGrade™ Hand Crimp Tool
Specification Sheet
Order No. 64016-0205
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
For crimps conforming to WHMA-IPCA620 Class 2, use hand crimp tools 11-01-
0185, 63811-3300, and/or 63811-7500.
SCOPE
Products: 0.156” KK™ and 0.062” pin and socket terminals, 18-30 AWG
0.062” Terminals
(WHMA-IPCA620 equivalent hand tool: 63811-3300)
Terminal Order No. Wire Size Insulation Diameter
Strip Length Terminal
Series No.
Loose Piece Reel AWG
mm² mm In. mm In.
02-06-2103
02-06-6119
02-06-2101
02-06-6118
02-06-6102
39-00-0327
02-06-6100
39-00-0278
02-06-6103
39-00-0330
02-06-6101
39-00-0329
1560
02-06-6104
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
02-06-1103
02-06-5109
02-06-1101
02-06-5105
02-06-5102
39-00-0331
02-06-1118
02-06-5108
02-06-5103
39-00-0334
02-06-5100
39-00-0279
1561
02-06-5104
02-06-5101
39-00-0333
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
02-06-2202
02-06-2201
1786 02-06-6202
02-06-6201
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
1787 02-06-1202
02-06-1201
02-06-5201
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
08-30-0110
08-34-0108
08-30-0109
08-35-0105
1799 08-34-0106
08-35-0106
08-34-0105
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
4529 02-06-1105
02-06-5208
02-06-1104
02-06-5207
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
5005 08-70-0042
08-70-0001
18-24
0.82-0.20
1.30-3.00
.051-.118
2.30-2.95
.090-.116
5006 08-70-0043
08-70-0002
18-24
0.82-0.20
1.30-3.00
.051-.118
2.30-2.95
.090-.116
0.062” Terminals
(WHMA-IPCA620 equivalent hand tool: 11-01-0185)
Terminal Order No. Wire Size Insulation Diameter
Strip Length Terminal
Series No.
Loose Piece Reel AWG
mm² mm In. mm In.
02-06-2132
02-06-6144
02-06-2131
02-06-6143
02-06-6135
04-01-0811
02-06-6130
04-01-0809
02-06-6136
39-00-0335
02-06-6137
39-00-0280
1854
02-06-6139
39-00-0337
02-06-6138
39-00-0336
24-30
0.20-0.05
1.02-2.29
.040-.090
3.17-3.96
.125-.156
02-06-1132
02-06-5148
02-06-1131
02-06-5147
02-06-5135
04-01-0812
02-06-1141
04-01-0810
02-06-5139
39-00-0339
02-06-1143
39-00-0338
39-00-0341
02-06-5130
39-00-0340
1855
02-06-5138
24-30
0.20-0.05
1.02-2.29
.040-.090
3.17-3.96
.125-.156
Hand Crimp TooHor0156"KKTM and 0.062" Termina‘s
Hand Crimp Tool for 0.156 KK and 0.062 Terminals
Doc No: ATS-640160205 Release Date: 06-03-08 UNCONTROLLED COPY Page 2 of 6
Revision: B Revision Date: 06-03-08
0.156” KK™
(WHMA-IPCA620 equivalent hand tool: 63811-7500)
Terminal Order No Wire Size Insulation Diameter
Strip Length Terminal
Series No
Loose Piece Reel AWG mm² mm In. mm In.
2477 08-50-0110
08-56-0114
08-50-0109
08-56-0113
18-24 0.80-0.20
1.39-2.79
.055-.110
2.54-3.17
.100-.125
08-50-0006
08-55-0134
08-50-0001
08-52-0073
08-50-0016
08-56-0106
08-50-0014
08-52-0114
08-50-0045
08-56-0154
08-50-0015
08-52-0811
08-50-0046
08-58-0104
08-50-0047
08-53-0004
08-50-0056
08-58-0115
08-50-0055
08-53-0811
08-50-0064
08-58-0122
08-50-0063
08-55-0103
08-50-0074
08-65-0115
08-50-0073
08-55-0133
08-50-0093
39-00-0342
08-50-0091
08-56-0105
08-50-0106
39-00-0344
08-50-0105
08-56-0153
08-50-0120
39-00-0348
08-50-0119
08-58-0103
08-50-0147
39-00-0350
08-50-0146
08-58-0114
08-52-0024
40-01-1120
08-50-0271
08-58-0121
08-52-0045
50-29-1762
08-50-0281
08-65-0114
08-52-0047
50-30-4428
08-51-0001
39-00-0286
08-52-0072
50-30-4429
08-51-0720
39-00-0343
08-52-0074
08-52-0023
39-00-0347
08-52-0115
08-52-0027
39-00-0349
08-52-0812
08-52-0044
40-01-1118
08-53-0812
08-52-0046
50-29-1689
2478
08-55-0104
08-52-0071
50-29-1768
18-24 0.80-0.20
1.39-2.79
.055-.110
2.54-3.17
.100-.125
08-50-0116
08-58-0128
08-50-0115
08-55-0138
08-52-0127
08-65-0119
08-51-0109
08-58-0127
08-52-0126
08-65-0118
2878
08-53-0814
18-20 0.80-0.50
1.52-2.79
.060-.110
2.54-3.17
.100-.125
08-50-0132
08-55-0143
08-50-0131
08-55-0142
08-55-0140
08-55-0146
08-55-0125
08-55-0145
4838
08-55-0141
08-55-0148
08-55-0139
08-55-0147
18-22 0.80-0.35
1.52-2.41
.060-.095
2.54-3.17
.100-.125
08-70-0013
08-70-1034
08-70-0012
5167 08-70-0097
18-24 0.80-0.20
1.39-2.48
.055-.098
2.54-3.17
.100-.125
08-50-0165
08-56-0139
08-50-0164
08-56-0135
08-51-0802
08-58-0189
08-51-0801
08-56-0137
6438
08-56-0133
08-53-0813
18-20 0.80-0.50
1.52-2.41
.060-.095
2.54-3.17
.100-.125
08-50-0029
08-58-0119
08-50-0024
08-58-0105
08-50-0189
08-58-0132
08-50-0026
08-58-0108
08-50-0251
08-60-0002
08-50-0028
08-58-0110
08-51-0107
50-29-1763
08-50-0187
08-58-0118
08-52-0113
50-29-1879
08-50-0275
08-58-0131
08-53-1102
08-51-0106
08-58-0187
08-58-0106
08-52-0112
08-60-0001
08-58-0109
08-53-1101
50-29-1639
6838
08-58-0111
08-58-0102
18-20 0.80-0.50
1.52-2.79
.060-.110
2.54-3.17
.100-.125
08-50-0023
08-58-0136
08-50-0008
08-58-0135
08-50-0706
08-65-0129
08-50-0705
08-65-0128
08-52-0132
08-52-0131
40-01-1181
8818
08-56-0188
08-56-0187
40-01-1182
18 - 22
0.80-0.35
1.52-2.79
.060-.110
2.54-3.17
.100-.125
8993 08-50-0276
08-50-0011
08-50-0277
18-24 0.80-0.20
1.39-2.79
.055-.110
2.54-3.17
.100-.125
Hand Crimp Tool for 0156" KKWI and 0.062" Termina‘s
Hand Crimp Tool for 0.156 KK and 0.062 Terminals
Doc No: ATS-640160205 Release Date: 06-03-08 UNCONTROLLED COPY Page 3 of 6
Revision: B Revision Date: 06-03-08
TERMINAL CENTERED
IN TOOL HOLDER
PRESS DOWN
LEVER TO OPEN
CONDUCTOR
GRIP
TERMINAL HOLDER
CLOSED ON TERMINAL
INSULATION GRIP
TERMIN
AL HOLDER
Crimping Information:
Crimp the terminal and appropriate gauge wire in the specified profile.
Wire Size Pull Force Min. Tool Crimp Profile
Terminal Series No
AWG mm2 N Lb. A B C
24 0.20 35.6 8.0
26 0.12 22.2 5.0
28 0.08 13.3 3.0
1854, 1855
30 0.05 8.9 2.0
18 0.82 89 20
20 0.52 58 13
22 0.32 35.6 8
1560, 1561, 1786, 1787,
4529, 5005, 5006
24 0.20 22 5
18 0.82 89 20
20 0.52 58 13
22 0.32 35.6 8
1799, 2478, 2878, 4838, 5167,
6438, 6838, 8818, 8993
24 0.20 28.9 6.5
Pull force test samples should not have the wire insulation crimped.
OPERATION
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can
occur to the tool or die.
Remove the terminal holder from the tool and set it aside.
Open the hand tool by squeezing the handles together; at the end of the closing stroke the anti-backup ratchet will
release. Release the handles and the hand tool will open.
Crimping Terminals
1. Select the desired terminal listed in the preceding charts.
2. Open the terminal holder by pressing down the lever and place the terminal in the holder.
Note: The above illustration is a general representation. Some of the terminals may look different and be held in a
different area of the terminal.
Hand Crimp TooHorO156"KKTM and 0.062" Termina‘s
Hand Crimp Tool for 0.156 KK and 0.062 Terminals
Doc No: ATS-640160205 Release Date: 06-03-08 UNCONTROLLED COPY Page 4 of 6
Revision: B Revision Date: 06-03-08
SHELF OF
HAND TOOL
CENTER TERMINAL OVER
CRIMP PROFILE
TERMINAL
HOLDER
CONDUCTOR ANVIL
WIRE
CENTER CONDUCTOR
GRIP OVER THE
CONDUCTOR ANVIL
SHELF OF
HAND TOOL
3. Release the lever to hold the terminal in place. See Figure 1.
4. Carefully place the terminal holder on the shelf of the hand tool and center the terminal as shown over the
appropriate tool crimp profile. See Figure 2.
Note: Some terminals may have a large insulation grip; extra care should be taken when loading these
terminals into the tool to avoid terminal damage.
5. Place a pre-stripped wire into the terminal (see Scope chart for
recommended strip lengths). Position the wire so the
conductor lies in the conductor grip.
6. While holding the wire in place, slowly close the handles of the
tool. If excessive resistance is felt, there may be a jam. If this
occurs, stop closing the tool and release the anti-backup
ratchet by lifting up the lever near the top of the moving handle.
See figure 3.
7. Continue to close the tool handles until the anti-backup ratchet
releases. Allow the handles to open.
8. Remove the crimped terminal and terminal holder from the tool.
9. Press down the lever on the terminal holder and remove the
crimped terminal.
10. Inspect the crimp for loose wire strands, missing crimp, or
other damage. Any minor terminal bending may be
straightened by hand.
Fig
ure
3
RATCHET
RELEASE
LEVER
LIFT UP
LEVER
Hand Crimp TooHorO156"KKTM and 0.062" Termina‘s
Hand Crimp Tool for 0.156 KK and 0.062 Terminals
Doc No: ATS-640160205 Release Date: 06-03-08 UNCONTROLLED COPY Page 5 of 6
Revision: B Revision Date: 06-03-08
Note:
An occasional, destructive, pull force test with the terminal and wire crimped should be performed to check hand
tool crimp. The pull force value must exceed the terminal’s minimum pull force specifications listed on page 3. If
values do not exceed the minimum pull force when all instructions are followed then a new tool is required.
Maintenance
It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance
steps:
1. Remove dust, moisture, and other contaminants with a
clean brush, or soft, lint free cloth.
2. Do not use any abrasive materials that could damage
the tool.
3. Make certain all pins; pivot points and bearing
surfaces are protected with a thin coat of high quality
machine oil. Do not oil excessively. Light oil (such as
SAE30W oil) applied at the oil points, shown in Figure
3, every 5,000 crimps or 3 months, is recommended.
4. Wipe excess oil from hand tool, particularly from
crimping area. Oil transferred from the crimping area
onto certain terminations may affect the electrical
characteristics of an application.
5. When tool is not in use, keep the handles closed to
prevent objects from becoming lodged in the crimping dies, and store the tool in a clean, dry area.
Miscrimps or Jams
If the tool ever becomes jammed in a partially closed position, DO NOT force the handles open or closed. The tool
will open by lifting the ratchet release lever. See Figure 2.
Tool Handle Preload
Tool handle preload cannot be adjusted.
This hand tool is set to a preload that will fully close the tool jaws without excessive force from the operator. Over
the life of the tool the tool linkage can wear and handle preload force may decrease. It is the operator’s
responsibility to periodically perform a tensile pull test on the crimped wire. If the pull test value falls below
specification, the tool should be replaced.
Fig
ure
3
Hand Crimp TooHor0156"KKTM and 0.062" Termina‘s CAUTIONS:
Hand Crimp Tool for 0.156 KK and 0.062 Terminals
Doc No: ATS-640160205 Release Date: 06-03-08 UNCONTROLLED COPY Page 6 of 6
Revision: B Revision Date: 06-03-08
Warranty
This tool is for electrical terminal crimping purposes only. All tools are warranted to be free of manufacturing
defects for a period of 30 days. Should such a defect occur, the tool will be exchanged free of charge. This
exchange will not be applicable to altered, misused, or damaged tools. This tool is designed for hand use only.
Any clamping, fixturing, or use of handle extensions voids this warranty.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.
CAUTIONS:
1. Manually powered hand tools are intended for low volume or field repair. This tool is NOT intended for
production use. Repetitive use of this tool should be avoided.
2. Insulated rubber handles are not protection against electrical shock. NEVER perform crimps on active
electrical circuits.
3. Wear eye protection at all times.
4. Use only the Molex terminals specified for crimping with this tool.
Certification
Molex does not certify or re-certify ServiceGrade™ hand tools but rather supplies the following guidelines for
customers to maintain their hand tools.
% This tool is qualified to pull force only. To re-certify, crimp a terminal to a wire, which has been stripped
12.7mm (1/2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than
25mm (1.00”) per minute. See the Molex web site for the Quality Crimp Handbook for more information on pull
testing.
% When the hand tool is no longer capable of achieving minimum pull force, it should be replaced.
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerinfo@molex.com
Far East North Headquarters
Yamato, Kanagawa, Japan
81-462-65-2324
feninfo@molex.com
Far East South Headquarters
Jurong, Singapore
65-6-268-6868
fesinfo@molex.com
European Headquarters
Munich, Germany
49-89-413092-0
eurinfo@molex.com
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: 630-969-1352
Visit our Web site at http://www.molex.com

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